Wire EDM

Custom Wire EDM Services

Introducing our specialized Custom Wire EDM services – where precision meets speed. At our core, we craft top-quality Wire EDM parts within days, not months. With an extensive network comprising numerous cutting-edge shops equipped with advanced wire EDM capabilities, we empower you with a virtually limitless capacity to produce simple and intricately designed components.

Experience the advantage of our rapid turnaround times, enabling you to bring your ideas to life without unnecessary delays. Whether it’s intricate aerospace components or precisely engineered parts for the medical industry, we’re equipped to meet your specific requirements with unparalleled accuracy.

  • Advanced Technology Precision
  • Cost-Efficient Complex Designs
  • Prototyping Expertise
Wire EDM - https://jiahuicustom.com/

What’s Wire EDM Process?

Wire EDM (Electrical Discharge Machining) stands as a sophisticated and precise manufacturing process that achieves intricate shaping and cutting of conductive materials with exceptional accuracy. This process, widely utilized across industries, holds significance for its ability to craft complex components with minimal mechanical stress and remarkable precision.

The process begins with the setup of a workpiece, commonly made of metal, and a thin, electrically charged wire. Both are submerged in a dielectric fluid. As the process commences, controlled electrical discharges are introduced, generating localized heat along the wire’s path. This heat melts minuscule portions of the workpiece, resulting in tiny craters. The melted material is then systematically flushed away by the surrounding dielectric fluid.

Guided by computer numerical control (CNC) systems, the wire is navigated along a programmed route, gradually removing material. This controlled erosion ensures that the desired shape evolves with meticulous accuracy. The process continues layer by layer, intricately carving out the final component.

Our Qualification For Wire EDM Service

With years of dedicated experience in this field, we stand as leaders in delivering top-notch Wire EDM services. Our skilled team, comprising experienced machinists and engineers, understands Wire EDM’s nuances in-depth. We are adept at working with various materials, including steel, aluminum, and plastics, ensuring we can cater to multiple project requirements.

Our state-of-the-art wire EDM machine is at the heart of our operations, a technological marvel that transforms digital designs into tangible products. Its impressive accuracy can achieve tolerances as tight as +/- 0.0001 inches, even when dealing with complex structures like threads, pockets, and slots. Furthermore, our vigilant quality control team diligently inspects and assesses each product to ensure it meets our stringent standards. This dedication to perfection guarantees that each component departing from our premises is of the utmost quality.

Manufacturing Process

The manufacturing process of Wire EDM at JIAHUI involves advanced precision. A thin, charged wire creates intricate cuts in conductive materials submerged in a dielectric fluid. Computer-controlled movements guide the wire, producing complex shapes with high accuracy. This process is ideal for industries requiring precision components with minimal stress.

Wire EDM-Manufacturing Process - https://jiahuicustom.com/
Material Cutting Slit Material Thickness Surface Finish Tolerance
Stainless Steel 0.1~0.2mm Generally 40~60mm, the thickest 600mm Ra1.25µm~ Ra2.5µm ±0.01~±0.02mm(±0.004mm achievable if specified)
Steel 0.1~0.2mm Generally 40~60mm, the thickest 600mm Ra1.25µm~ Ra2.5µm ±0.01~±0.02mm(±0.004mm achievable if specified)
Aluminum 0.1~0.2mm Generally 40~60mm, the thickest 600mm Ra1.25µm~ Ra2.5µm ±0.01~±0.02mm(±0.004mm achievable if specified)
Titanium 0.1~0.2mm Generally 40~60mm, the thickest 600mm Ra1.25µm~ Ra2.5µm ±0.01~±0.02mm(±0.004mm achievable if specified)

Our Wire EDM Production Capabilities

Whether a small batch or a large-scale production, our turnaround times are as swift as 24 hours, reflecting our commitment to efficiency. So, elevate your projects with our CAD/CAM design expertise, tooling solutions, and impeccable finishing.

Materials for Wire EDM Parts

Wire EDM boasts diverse material capabilities, encompassing steel (carbon, stainless, tool), aluminum (with its inherent softness), brass (a copper-zinc alloy), plastic (a non-metallic choice), and more (like titanium, tungsten, molybdenum). Material selection hinges on strength, conductivity, cost, and specific application needs. Expert guidance aids informed choices for optimal wire EDM part results.

  • Alloy Steel
  • Stainless Steel
  • Aluminum
  • Copper
  • Titanium

Alloy Steel

Alloy Steel

Alloy steel is a type of steel that incorporates additional elements, such as chromium, nickel, or molybdenum, to enhance its mechanical properties. These alloys impart improved strength, hardness, and resistance to wear, corrosion, and heat, making alloy steel suitable for various applications in industries like automotive, construction, and aerospace.

Characteristics

  • High strength
  • Improved hardness
  • Enhanced corrosion resistance
  • Heat resistance
  • Versatility for various applications

 

Stainless Steel

Stainless Steel

Stainless steel is metal-enriched with chromium elements (11%) and a small amount of carbon. Chromium offers corrosion resistance to stainless steel. Due to this, the wire EDM parts are less likely to be affected by rust or corrosion. It can be easily molded into several forms. Thus, manufacturers prefer it for the die-casting process.

Characteristics

  • Extremely durable
  • High tensile strength
  • Corrosion resistant
  • Easy fabrication and formability
  • Low maintenance cost

AluminumAluminum

The distinctive characteristics of aluminum make it one of the best materials for wire EDM. The major aluminum alloys are A360, A380, A390, A413, ADC12, and ADC1. Among all, the A380 is the most worthwhile aluminum alloy.

Characteristics

  • Excellent corrosion resistance
  • Lightweight
  • High strength and hardness
  • Outstanding thermal conductivity
  • High electrical conductivity
  • Remarkable EMI and RFI shielding properties

CopperCopper

Copper is a reddish-orange metal with a face-centered cubic structure that is highly valued for its aesthetics. It exhibits remarkable properties, yet, it can be alloyed with different elements, such as aluminum, tin, zinc, nickel, etc., to improve its characteristics further. The following are some fundamental properties of copper that make it ideal for producing die-casting parts.

Characteristics

  • Very soft
  • An excellent conductor of heat and electricity
  • Good corrosion resistance
  • High ductility
  • Fine malleability

 

Titanium - https://jiahuicustom.com/

Titanium

Titanium is a silver-grey transition metal often used for manufacturing high-strength parts. It is relatively soft when present in its pure form. However, adding certain elements like iron, aluminum, and vanadium makes titanium harder. The properties of titanium make it a perfect choice for manufacturers to use for die-casting parts.

Characteristics

  • Extremely high tensile strength
  • Lightweight
  • High corrosion resistance
  • Able to withstand extreme temperatures
  • High melting point
  • Excellent oxidation capabilities

 

Surface Treatment For Wire EDM Parts

Our Wire EDM parts can undergo meticulous surface treatments to meet your desired specifications. From mirror-like finishes to protective coatings, we offer a range of treatments to enhance durability, corrosion resistance, and aesthetic appeal.

Name
Product
Description
Materials
Color
Texture

Micro-arc Oxidation (MAO)

Micro-arc Oxidation_Wire EDM - https://jiahuicustom.com/

MAO is a surface treatment method that uses high-voltage electrical discharges to create a ceramic-like coating on metal surfaces. This process involves the formation of a dense and hard oxide layer, which enhances the material's corrosion resistance, wear resistance, and thermal stability.

Aluminum, Magnesium, Titanium, Zinc

Black, Grey

Smooth, Matte finish

Anodizing

Anodizing_Wire EDM - https://jiahuicustom.com/

Anodizing improves corrosion resistance, enhancing wear and hardness and protecting the metal surface. This surface finish is widely used in mechanical parts, aircraft, automobile parts, and precision instruments.

Aluminum, Magnesium, Titanium

Clear, Black, Grey, Red, Blue, Gold, White, Silver, purple

Smooth, Matte finish

Bead Blasting

Bead Blasting_Wire EDM - https://jiahuicustom.com/

Bead blasting in surface treatment is a process where fine abrasive particles, such as glass beads or ceramic media, are propelled at high speed onto a surface using compressed air. This abrasive action helps to remove rust, paint, or other contaminants, leaving behind a clean and textured surface finish.

ABS, Aluminum, Brass, Stainless Steel, Steel

Clear

Smooth, Matte finish

Powder Coating

Powder Coating_Wire EDM - https://jiahuicustom.com/

Powder coating in surface treatment is a dry finishing process where a fine powder is electrostatically applied to a surface. The coated object is then cured under heat, melting the powder particles and forming a durable, smooth, uniform coating.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Vertical stripe

Smooth, Matte finish

Electroplating

Electroplating_Wire EDM - https://jiahuicustom.com/

Electroplating in surface treatment is when a metal coating is applied to a conductive surface through an electrochemical reaction. It involves immersing the object to be plated in a solution containing metal ions and using an electric current to deposit a metal layer onto the surface.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Clear, White, Black, Grey, Red, Yellow, Blue, Green, Gold, Silver, Bronze

Smooth, Semi-matte, Matte finish

Polishing

Polishing_Wire EDM - https://jiahuicustom.com/

Polishing is the process of creating a shiny and smooth surface, either through physical rubbing of the part or by chemical interference. This process produces a surface with significant specular reflection but can reduce diffuse reflection in some materials.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Clear

Smooth, Mirror finish

Brushing

Brushing_Wire EDM - https://jiahuicustom.com/

Brushing in surface treatment refers to manually or mechanically applying abrasive brushes to a surface, usually metal, to remove imperfections, create a uniform texture, or enhance its appearance.

Stainless Steel, Fe-based Alloy Steel, Copper Alloy, Nickel-base Alloy, Titanium, Hard Alloy

Clear

Smooth, Matte finish

Electrophoresis

Electrophoresis - https://jiahuicustom.com/

Electrophoresis is a process in which charged resin particles (ions) in a solution are moved by an electric field and deposited on a metal surface to form a protective coating.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Laser Carving

Laser Carving_Wire EDM - https://jiahuicustom.com/

Laser carving is a surface finish method that utilizes laser technology to etch or engrave intricate designs onto a material's surface. It offers precise and detailed patterns, making it suitable for aesthetic enhancements or functional purposes, and is commonly used in various industries such as manufacturing, jewelry, and art.

Stainless Steel, Fe-based Alloy Steel, Copper Alloy, Nickel-base Alloy, Titanium, Hard Alloy

Clear, Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Painting

Painting_Wire EDM_Optical Equipment Industrial parts - https://jiahuicustom.com/

Painting is especially suitable for the surface of the primary material of metal. It will strengthen the material's moistureproof& rust prevention functions and enhance its compression resistance and internal structural stability.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Excellent Wire EDM Services

Our approach is rooted in instilling quality throughout the manufacturing process, and our standard practice involves meticulously inspecting each component.

Typical Wire EDM Products

Die Casting FAQs - https://jiahuicustom.com/

FAQs Related To Wire EDM

A: Wire EDM (Electrical Discharge Machining) is a precision cutting method that uses a thin, electrically conductive wire to cut through various materials. There are two primary cutting methods used in Wire EDM:

  1. Contour Cutting: The Wire follows this method's desired path to cut intricate shapes and contours. The Wire is guided by a computer-controlled system, moving in multiple directions to create precise cuts and intricate shapes.
  2. Taper Cutting: Taper cutting involves tilting the Wire at an angle to create tapered or angled cuts. This method is used when precise taper angles are required, such as to generate draft angles on molds or cut angled features in parts.

Both cutting methods in Wire EDM offer high precision and can achieve intricate cuts in various materials, including conductive and non-conductive materials.

A: Several factors can affect the surface quality of workpieces processed by Wire EDM. Some of the key factors include:

  1. Wire type and diameter: The choice of wire material and its diameter can impact the surface finish. Different wire types have varying levels of hardness and conductivity, which can affect the cutting speed and surface quality.
  2. Cutting speed: The speed at which the wire moves during cutting can affect the surface finish. Higher cutting speeds may result in rougher surfaces, while slower speeds can produce smoother finishes.
  3. Wire tension: Proper wire tensioning is essential for maintaining stable cutting conditions. Inadequate tension can lead to vibration and irregularities on the workpiece surface.
  4. Flushing conditions: The flushing medium, such as dielectric fluid, used during the Wire EDM process can impact the surface quality. Proper flushing helps remove debris and prevents recast layers that can affect the surface finish.
  5. Pulse settings: Parameters like pulse duration, frequency, and current intensity can influence the surface quality. Optimal pulse settings ensure efficient material removal without excessive heat generation.
  6. Workpiece material: Different materials have varying properties, such as hardness and thermal conductivity, which can affect the surface finish. Harder materials may require different cutting parameters to achieve the desired surface quality.
  7. Wire alignment and wear: Proper wire alignment and regular inspection for wear is crucial for maintaining consistent cutting and surface quality.

Optimizing these factors and selecting appropriate cutting conditions can help achieve the desired surface quality in Wire EDM processed workpieces.

A: The precision requirements for medium-feeding Wire EDM machines typically depend on the specific application and the desired level of accuracy. However, several general requirements are common for achieving high precision:

  1. Positioning accuracy: The machine should have precise positioning capabilities to move the wire and workpiece accurately. This includes controlling the wire movement in multiple axes with high repeatability.
  2. Wire tension control: The machine should have a reliable wire tensioning system to ensure consistent tension throughout the cutting process. Proper tension control helps maintain stable cutting conditions and prevents wire breakage.
  3. Wire alignment: Accurate wire alignment is crucial for achieving precise cuts. The machine should have mechanisms for aligning the wire in multiple axes to ensure it accurately follows the desired cutting path.
  4. Control system: The machine's control system should be capable of fine-tuning and adjusting cutting parameters, such as cutting speed, pulse settings, and flushing conditions. This allows for precise control of the cutting process to achieve the desired level of accuracy.
  5. Stability and rigidity: The machine's structure should be stable and rigid to minimize vibrations and ensure consistent cutting performance. Any unwanted movement or flexing can negatively impact the precision of the cuts.
  6. Feedback systems: The machine should be equipped with feedback systems, such as linear encoders or laser interferometers, to provide accurate position feedback and enable closed-loop control for enhanced precision.

Meeting these precision requirements ensures that the medium-feeding Wire EDM machine can achieve the desired level of accuracy for cutting complex shapes and achieving tight tolerances.

A: A short circuit can occur in a Wire EDM machine for several reasons. Here are a few possible causes:

  1. Wire breakage: If the wire breaks during the cutting process and the broken ends come into contact, it can result in a short circuit. This can happen due to excessive tension, improper wire alignment, or excessive wear on the wire.
  2. Wire threading issues: When threading a new wire into the machine, it can cause the wire to touch itself and create a short circuit if it is not aligned correctly or gets stuck.
  3. Poor insulation: Insulation failure or damage in the machine's wire guides, power supply, or other components can lead to a short circuit. 
  4. Contamination or debris: If foreign materials, such as metal chips, coolant residue, or dust, accumulate on the wire or cutting area, it can cause a short circuit. These contaminants can bridge the gap between the wire and the workpiece, resulting in a connection and a short circuit.
  5. Electrical faults: Malfunctioning electrical components, such as the power supply, servo motors, or control circuits, can cause short circuits. This can be due to wiring issues, component failure, or improper electrical connections.

It is important to regularly inspect and maintain the machine to prevent short circuits during Wire EDM operation. This includes proper wire threading, maintaining wire tension within recommended limits, ensuring adequate insulation, and keeping the cutting area clean from debris. Regular calibration and maintenance of electrical components are also crucial to prevent electrical faults.

A: The electrode wire used in Wire EDM (Electrical Discharge Machining) can significantly influence the cutting speed and overall machining performance. Here are the critical factors related to the electrode wire that can affect Wire EDM speed:

  1. Diameter of the wire: The diameter of the electrode wire plays a crucial role in determining the cutting speed. Thicker wires can withstand higher cutting currents and allow faster material removal, resulting in higher cutting speeds. However, thicker wires may result in reduced precision.
  2. Material of the wire: Different materials are used for electrode wires in Wire EDM, such as brass, copper, or coated wires. The material choice can impact the cutting speed. For instance, brass wires are commonly used for general-purpose cutting, while coated wires, such as zinc-coated or tungsten-coated wires, can offer improved cutting speed and wear resistance.
  3. Wire tension: Proper wire tension is essential for maintaining stable cutting conditions and achieving optimal cutting speeds. Insufficient tension can cause wire breakage, while excessive tension can lead to wire deviation and slower cutting speeds. Maintaining the correct tension is crucial for maximizing cutting efficiency.
  4. Wire flushing: The wire EDM process employs a dielectric fluid for flushing away the eroded particles. Efficient wire flushing helps remove the debris from the cutting area and facilitates faster material removal. Proper selection and adjustment of flushing parameters, such as flow rate and pressure, are essential for achieving higher cutting speeds.
  5. Wire wear and maintenance: The electrode wire gradually wears out over time due to the cutting process. As the wire wears down, the cutting speed may decrease, requiring adjustments in the machining parameters to maintain consistent cutting speeds. Regular wire inspection and replacement are necessary to maintain optimal cutting performance.

It is important to note that the cutting speed in Wire EDM results from various factors, including the material being cut, desired accuracy, machine capabilities, and specific machining conditions. Optimization of all these factors, including the electrode wire, is essential for achieving the desired cutting speed and overall machining efficiency.

A: Yes, medium-feeding Wire EDM machines can successfully realize automatic wire threading. Automatic wire threading (AWT) is a feature in Wire EDM machines that allows for the automatic threading of a new electrode wire into the machine after the previous wire has been used up or broken.

Medium-feeding Wire EDM machines typically use a wire spool or a wire drum to feed the electrode wire. These machines are designed with mechanisms that facilitate the automatic threading process. Here's how it generally works:

  1. Wire break detection: When the machine detects the broken wire, it pauses the machining operation and activates the automatic wire threading sequence.
  2. Wire guide alignment: The machine moves the wire guides into position, aligning them to create a straight path for the new wire to thread through.
  3. Wire threading process: The machine uses various mechanisms, such as wire clamps, pulleys, and threading guides, to thread the new wire through the wire guides, power contacts, and other necessary components.
  4. Wire tension adjustment: Once the new wire is threaded, the machine adjusts the tension to the appropriate level for cutting operations.
  5. Resumption of machining: After successful wire threading, the machine resumes the machining process, continuing from where it left off.

It is important to note that the specific steps and mechanisms involved in automatic wire threading can vary depending on the machine manufacturer and model. To enhance efficiency and reliability, some machines may have additional features, such as wire auto-recovery or wire break detection during threading.

Automatic wire threading in medium-feeding Wire EDM machines helps minimize downtime and manual intervention, improving productivity and reducing the need for operator intervention. However, following the manufacturer's guidelines and instructions for the proper setup and operation of the automatic wire threading feature is crucial.

A: Choosing the processing parameters for Wire EDM (Electrical Discharge Machining) involves several considerations to achieve optimal cutting performance and desired results. Here are some key factors to consider when selecting Wire EDM processing parameters:

  1. Material being cut: Different materials have different electrical conductivity, melting points, and other properties that affect the machining process. Refer to the material's technical data or consult with the material supplier to determine the appropriate cutting parameters.
  2. Desired accuracy and surface finish: The level of precision and surface finish required for the part will influence the choice of cutting parameters. Finer finishes generally require slower cutting speeds and smaller wire diameters.
  3. Wire diameter: The wire diameter affects the cutting speed, precision, and surface finish. Thicker wires allow faster cutting speeds but may sacrifice precision and surface finish. Thinner wires provide finer accuracy and smoother surfaces but may reduce cutting speed.
  4. Cutting speed: The cutting speed determines the rate at which the material is removed. It depends on wire diameter, material type, and desired surface finish. Higher cutting speeds result in faster material removal but may impact accuracy and surface finish.
  5. Gap voltage: Gap voltage refers to the electrical potential between the wire electrode and the workpiece. It affects the intensity of the electrical discharge and the material removal rate. The optimal gap voltage depends on material type, wire diameter, and desired cutting speed.
  6. Flushing conditions: Proper flushing is crucial for removing debris from the cutting area and maintaining cutting efficiency. Adjusting flushing parameters such as flow rate, pressure, and dielectric fluid type can help optimize the cutting process.
  7. Wire tension: Maintaining proper wire tension is essential for stable cutting conditions. Insufficient tension can lead to wire breakage, while excessive tension can cause wire deviation. Follow the machine manufacturer's guidelines for setting the appropriate wire tension.

When selecting Wire EDM processing parameters, it is essential to consult the machine manufacturer's guidelines, technical specifications, and cutting parameter charts. Additionally, conducting initial test cuts and adjusting parameters based on the results can help fine-tune the process for optimal performance.

A: The working fluid, also known as the dielectric fluid, used in Wire EDM significantly impacts the cutting speed and overall performance of the machining process. Here are the effects of working fluid on Wire EDM speed:

  1. Heat dissipation: The working fluid serves as a coolant during the Wire EDM process, helping to dissipate the heat generated by the electrical discharges. Effective heat dissipation is crucial to prevent overheating and maintain stable cutting conditions. A proper cooling effect the working fluid provides allows for higher cutting speeds.
  2. Debris removal: The working fluid flushes away the molten metal debris and other particles produced during cutting. Efficient debris removal helps maintain a clean cutting zone, reducing the risk of short circuits and improving cutting speed and accuracy.
  3. Dielectric breakdown voltage: Dielectric breakdown voltage refers to the voltage at which the dielectric fluid loses its insulating properties and allows electrical discharges to occur. The dielectric fluid used in Wire EDM should have a sufficiently high breakdown voltage to prevent premature electrical discharges. A high breakdown voltage allows for higher cutting speeds and reduces the risk of sparking and wire breakage.
  4. Flushing efficiency: The working fluid's flushing properties affect debris removal efficiency and the maintenance of a clean cutting zone. Proper flushing helps prevent the accumulation of debris and improves cutting speed and accuracy.
  5. Lubrication: The working fluid also acts as a lubricant between the wire electrode and the workpiece, reducing friction and wear. Adequate lubrication can help maintain stable cutting conditions and prevent wire deviation, allowing for higher cutting speeds.

It is essential to use the recommended dielectric fluid specified by the machine manufacturer for optimal cutting speed and performance. Additionally, monitoring and maintaining the quality and condition of the working fluid, such as proper filtration and regular replacement, is essential to ensure consistent and efficient Wire EDM operations.

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